The Need For Cleaner Diesel Fuel

The Need For Cleaner Diesel Fuel

Rick Chapman NCWM National Meeting

Philadelphia, PA July 22, 2015

Agenda • CRC Report No. 667 Diesel Storage & Handling Guide - Summary • ASTM Diesel Fuel Cleanliness Workshop

– Overview

– General Fuel User Theme

– “Customer Focus”

• Injector Manufacturers

• Light Duty Diesel Producers

• Heavy Duty Diesel and Engine Manufacturers

Coordinating Research Council (CRC) Report No. 667 Summary

• Report emphasizes how to handle and store diesel fuel in order to maintain it’s cleanliness from the point of production to the end customer user. It intends to provide the best available information for general housekeeping.

• The guide’s The report can be downloaded at: http://www.crcao.org/reports/recentstudies2014/CRC%20667/CRC%20667.pdf

http://www.crcao.org/reports/recentstudies2014/CRC%20667/CRC%20667.pdf

http://www.crcao.org/reports/recentstudies2014/CRC%20667/CRC%20667.pdf

• Rick Chapman, Innospec Fuel Specialties (Team Leader)

• Norm Blizard, Cummins Engine

• Ed English, Fuel Quality Services

• Roger Gault, Truck & Engine Manufacturers Association (EMA)

• Garry Gunter, Phillips 66

• Roger Leisenring, Leisenring Fuels Consulting

• Russ Lewis, Marathon Petroleum

• Tom Livingston, Robert Bosch

• Shailesh Lopes, GM Powertrain

• Manuch Nikanjam, Chevron

• Fred Passman, Biodeterioration Control Services (BCA)

• Steve Westbrook, Southwest Research Institute (SWRI)

Coordinating Research Council (CRC) Report No. 667 List of Authors

ASTM Cleanliness Workshop Overview • Held in response to CRC Report 667 “Diesel Fuel Storage &

Handling Guide”

• Goal was to bring fuel manufacturers, distributors, end users, regulators and other interested parties together to seek ways to maintain adequate diesel fuel cleanliness throughout the distribution system and as required by modern engines.

• Significant time was held at the workshop’s end for open discussion regarding what changes may be required to improve fuel cleanliness. Many good ideas were discussed.

• There were roughly 150 attendees from many areas -- fuel manufacturers, distributors, users, regulators, etc.

ASTM Diesel Cleanliness Workshop Topic and Speaker List

• “User Perspective: Why Clean Fuels Matter” –

o Roger Gault, EMA; Tom Livingston, Bosch; Dr. Shailesh Lopes, GM

• “Fuel Manufacture, Distribution and Storage Perspective” – Russ Lewis, Marathon

• “Regulator-NCWM Perspective on Clean Diesel Fuel” – Ron Hayes, State of MO

• “Water & Microbial Effects on Fuel Cleanliness” – Dr. Fred Passman, Biodeterioration Control Associates

• “Diesel Fuel Corrosion” – Ed English, Fuel Quality Services

• “Types of Diesel Fuel Contaminants” – Steve Westbrook, SWRI

• “Housekeeping, Maintenance and the Importance of System Filtration” – Russ Lewis, Marathon

• “Specifications: The Importance of Keeping Fuel Specs Up to Date and Relevant” – Roger Gault, EMA

• “User Experience: Clean Fuels Makes a Difference” – Norm Blizard, Cummins

ASTM Cleanliness Workshop -- Customer Focus • To meet customer demands and mandated regulatory emissions,

diesel engines now must use High Pressure Common Rail (HPCR) fuel injection systems:

• In order to get the higher pressures needed for better fuel atomization and combustion, injector metal-to-metal tolerances have to be very small (typically ~2 microns).

• It is therefore critical that fuel must be clean and dry for these systems to work properly and without damage. This is true for both Light and Heavy Duty diesel engines.

• Other important considerations are:

• Fuel must have acceptable chemistry to avoid creation of soaps, corrosion, sludge, or other deposits – very difficult to guard against

• Fuel must have correct cold flow properties for the season

• Next generation engines will be even more dependent on clean fuels

DS/ENS1-NA-TL | 4/29/2015 | ENS final | © 2015 Robert Bosch LLC and affiliates. All rights reserved.

ASTM Diesel Fuel Cleanliness Workshop, June 2015

Diesel Systems

… so, where does Clean Diesel Fuel Matter?

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Fuel Injection System Manufacturer Perspective ASTM Diesel Fuel Cleanliness Workshop, June 2015

Diesel Systems

Why Clean Diesel Fuel Matters…

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Diesel Systems

Particle erosion

• On-board fuel filtration has improved fuel cleanliness as supplied to the injection system. These necessary changes have resulted in greater sensitivity to the fuel cleanliness delivered to the vehicle

• Figures: Particle erosion in a common rail injector

Source: CRC report 667 DF Storage & Handling Guide

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Diesel Systems

Corrosion

• Field common rail fuel injection equipment returns places corrosion in top 3 of fuel related complaints.

Fuel rail & components Source: CRC report 667 DF Storage & Handling Guide

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3. Melting of armature as result of pump running dry due to dirty filter

2. Fuel control valve on injector with severe hard particle erosion

• Particulates > 5 microns cause wear and deposit formation in common rail fuel systems

• Majority of particulates > 5 microns are in the range of 5-10 microns

• Approximately 15- 32% of > 5 micron particles are > 10 microns which would be removed by 10 micron dispenser filters

• Only 1-2 % of particulates are > 25 microns. A majority of these particulates are filtered by 30 micron fuel filters

• A greater number of survey samples would show more instances of severe contamination

• End Result – 10 micron filters offer better protection than 30 micron ones

• Greater efficiency dispenser filters (> 90% at 10 microns) are necessary to reduce expensive vehicle hardware issues due to particulates.

• 10 micron filters are incrementally better than 30 micron ones in preventing debris from being passed along to vehicle customers

• U.S. market fuel survey data: 2013 – 2014 SGS Data:

• Largest percent of sediment is between 5 and 10 microns

• 10 micron filters would be 8 – 57 times more effective than 25 micron filters to remove larger particulates

• Even with high quality fuels, some fuel particulate forms in the service station tank as a result of ageing, i.e. corrosion, wear, material flaking, etc.

• Therefore fine filter media are needed to prevent passing it along downstream

• Use of coalescencer dispenser filter media would be best to protect consumers from water contaminated fuels

GM’s Position on Service Station Diesel Fuel Filters

Excerpt from ASTM Diesel Cleanliness Workshop Cummins Closing remarks

There is worldwide recognition of the need for clean and dry fuels for modern fuel systems

• Customers are accepting this and improving fuel quality through better specification, filtration, water separation and handling.

• Productivity and “uptime” improvements as well as reduced cost of ownership and out of warranty repairs are key motivators

• This trend is expected to continue as Tier 4 engines emerge in the market segments

ASTM Diesel Cleanliness Workshop – June 25 2015 18

Conclusions • Tighter emissions requirements, increased customer demands

and new HPCR injection systems dictate that clean diesel fuel is essential to damage-free engine operation

• The fuel industry is recognizing engine manufacturers need for cleaner diesel and is taking steps to provide it

• All involved parties must do their part to in keeping diesel clean and dry and should “pass it on no dirtier than they received it”

• Russ Lewis of Marathon will now give a more in-depth focus of fuel distribution systems with emphasis on retail USTs.

Documents

The Need For Cleaner Diesel Fuel